electrical - justanswerww2.justanswer.com/uploads/rocketboat/2008-12-30_025650...2008/12/30 ·...

A2

55042

ELECTRICAL

IGNITION

2A-0 - ELECTRICAL 90-852572R02 NOVEMBER 2002

Table of ContentsPage

Specifications 2A-1. . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 2A-2. . . . . . . . . . . . . . . . . . . . . . . . . . Notes: 2A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel And Stator (Electric) 2A-4. . . . . . . . . . . . Flywheel And Stator (Manual) 2A-5. . . . . . . . . . . . Electrical Components 40/50 2A-6. . . . . . . . . . . . Electrical Components 55/60 2A-8. . . . . . . . . . . . Theory of Operation 2A-10. . . . . . . . . . . . . . . . . . . .

Capacitor Charging #1 CDM 2A-10. . . . . . . . . . Capacitor Charging #2 & #3 CDM 2A-11. . . . . . #1 Cylinder Trigger Circuit 2A-12. . . . . . . . . . . . Ignition Coil Circuit 2A-13. . . . . . . . . . . . . . . . . . . Stop Circuit 2A-14. . . . . . . . . . . . . . . . . . . . . . . . . Rev Limiter Circuit 2A-15. . . . . . . . . . . . . . . . . . .

Ignition Component Description 2A-16. . . . . . . . . . Capacitor Discharge Module (CDM) 2A-16. . . . Trigger Coil 2A-16. . . . . . . . . . . . . . . . . . . . . . . . . Stator Assembly 2A-16. . . . . . . . . . . . . . . . . . . . . Flywheel 2A-16. . . . . . . . . . . . . . . . . . . . . . . . . . .

CDM (P/N 827509A) Trouble Shooting 2A-17. . . . Chart 1- CDM Trouble Shooting Flowchart 2A-17. . . . . . . . . . . . . . . . . . . . . . . . . . CDM Stop Diode Trouble Shooting 2A-18. . . . . Chart 2-CDM Trouble Shooting Flowchart 2A-19. . . . . . . . . . . . . . . . . . . . . . . . . . Chart 3-CDM Trouble Shooting Flowchart 2A-21. . . . . . . . . . . . . . . . . . . . . . . . . . CDM Test with DMT 2000 Multi-meter91-854009A01 2A-22. . . . . . . . . . . . . . . . . . . . . . CDM Test with Volt/Ohm/DVA Meter91-99750A1 2A-23. . . . . . . . . . . . . . . . . . . . . . . .

Ignition Test Procedures 2A-24. . . . . . . . . . . . . . . . . Direct Voltage Adaptor (DVA) Test 2A-24. . . . . Resistance Tests 2A-25. . . . . . . . . . . . . . . . . . . .

Flywheel Removal and Installation 2A-26. . . . . . . . Stator Removal and Installation 2A-27. . . . . . . . . .

Trigger 2A-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CDM 2A-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90-852572R02 NOVEMBER 2002 ELECTRICAL - 2A-1

Specifications

IGNITION SYSTEM

TypeSpark Plug Type

Spark Plug GapFiring Order

Capacitor DischargeNGK BP8H-N-10

*NGK BPZ8H-N-10NGK BUZ8H

NGK BP8HS-100.040 in. (1.0mm)

1-2-3

TIMING

IdleMaximum Timing

@ Cranking Speed-Model 40/50/60-Model 55/60 Seapro-Marathon

@ 5000 RPM– Model 40/50/60– Model 55/60 Seapro-Marathon

T.D.C. ± 2°

24° B.T.D.C.18° B.T.D.C.

22° B.T.D.C.16° B.T.D.C.

*Suppressor (resistor) spark plug


Special Tools1. Flywheel Holder 91-52344

2. Flywheel Puller 91-849154T1

3. 91-99750A1 Multi Meter/DVA Tester

4. DMT 2000 Digital Tachometer Multi-meter91-854009A01

5. DVA Adaptor 91-89045-1

6. Spark Gap Tester 91-63998A1

7. TPI/CDM Test Harness 84-825207A2

8. Spark Gap Tester 91-850439

9. DVA Adaptor 91-89045

91-89045


Notes:


Flywheel And Stator (Electric)

1

2

3

4

5

6

7

1010892-4-C with Teflon95

Loctite 222 Thread Locker51

51

95

11

REFTORQUE

REF.NO. QTY. DESCRIPTION lb. in. lb. ft. N·m

1 1 FLYWHEEL COVER

2 1 NUT 100 135.63 1 WASHER4 1 FLYWHEEL5 1 STATOR6 4 SCREW (M5 x 30) 60 6.87 1 TRIGGER8 1 SWIVEL BALL

9 1 SWIVEL BASE10 2 CABLE TIE11 1 DECAL-EPA INFORMATION


Flywheel And Stator (Manual)

9

9

10

1

2

3

4

5

6

7

8

2-4-C with Teflon95

Loctite 222 Thread Locker51

95

51

REFTORQUE

REF.NO. QTY. DESCRIPTION lb. in. lb. ft. N·m

1 1 FLYWHEEL2 1 NUT 100 135.63 1 WASHER

4 1 STATOR5 4 SCREW (M5 x 30) 60 6.86 1 TRIGGER7 1 SWIVEL BALL8 1 SWIVEL BASE9 2 CABLE TIE10 2 PLUG


Electrical Components 40/50

8

11

12

13

6

14

36

37

38

39

40

1

25

9

10

15

19

31

16

28

5

2

23

1718

35

24

32

33

41

29

30

23

7

7

4

27

42

34

2021

18

1312

43

26

3

22

22

25 Liquid Neoprene

2525

25

25

25

25


Electrical Components 40/50REF

TORQUEREF.NO. QTY. DESCRIPTION lb. in. lb. ft. N·m

1 1 PLATE–Electrical2 1 SCREW (M5 x 12) 40 4.53 1 WASHER4 1 STA–STRAP

51 REV LIMITER (MANUAL)

51 REV LIMITER

6 1 CLAMP7 3 SCREW (M5 x 12) 40 4.58 1 SOLENOID ASSEMBLY9 2 BUSHING10 2 GROMMET11 2 SCREW (M6 x 25) ELECTRIC 60 6.812 2 NUT (1/4-20) 30 3.413 2 LOCKWASHER14 1 CABLE15 1 CABLE16 2 NUT 20 2.317 1 VOLTAGE REGULATOR18 2 SCREW (M6 x 35) 60 6.819 1 J CLAMP20 1 BOOT21 1 BATTERY CABLE (NEGATIVE)22 1 WASHER (QTY. OF 3 ON ELECTRIC)23 AR STA–STRAP24 2 SCREW (M6 x 25) 40 4.525 1 CABLE26 1 SCREW (M8 x 20)(MANUAL) 30 3.427 1 SCREW (M6 x 10)(MANUAL) 60 6.828 2 J CLAMP (QTY. OF 3 ON ELECTRIC)29 1 HARNESS ASSEMBLY–Engine (ELECTRIC)30 1 FUSE31 3 GROMMET32 3 BUSHING33 3 WASHER34 3 SCREW (M6 x 25) 100 11.335 1 HARNESS-Ignition

362 CDM ASSEMBLY (5 IN. LEADS)

361 CDM ASSEMBLY (8 IN. LEADS)

37 3 HI-TENSION CABLE38 3 BOOT

3 SPARK PLUG (NGK# BP8H-N-10) 20 27.139 3 SPARK PLUG (NGK#BPZ–8H–N–10) 20 27.139

3 SPARK PLUG (NGK#BUZ8H) 20 27.140 6 SCREW (M6 x 14) 60 6.841 1 HARNESS-Power (MANUAL)42 1 HARNESS

431 HARNESS ASSEMBLY. -Adaptor (MANUAL)

431 HARNESS ASSEMBLY. -Adaptor (ELECTRIC)


Electrical Components 55/60

8

9

10

11

1213

17

18

28

36

37

38

39

40 1

25

23

41

29

30

5

6

14

15

19

16

7

20

21

2

24

3233

4

27

42

34

18

13

12

7

23

3

22

22

6

25

55 HP ONLY

25

25

25

25

25

26

31

25 Liquid Neoprene (92-25711--2)

Dielectric Grease (92-823506--1)6

35

43


Electrical Components 55/60REF

TORQUEREF.NO. QTY. DESCRIPTION lb. in. lb. ft. N·m

1 1 PLATE–Electrical2 1 SCREW (M5 x 12) 40 4.53 1 WASHER4 1 STA–STRAP

51 REV LIMITER (MANUAL)

51 REV LIMITER

6 1 CLAMP7 3 SCREW (M5 x 12) 40 4.58 1 SOLENOID ASSEMBLY9 2 BUSHING10 2 GROMMET11 2 SCREW (M6 x 25) 60 6.812 2 NUT (1/4-20) ELECTRIC 30 3.413 2 LOCKWASHER14 1 CABLE15 1 CABLE16 2 NUT 20 2.317 1 VOLTAGE REGULATOR18 2 SCREW (M6 x 35) 60 6.819 1 J CLAMP20 1 BOOT21 1 BATTERY CABLE (NEGATIVE)22 2 WASHER23 AR STA–STRAP24 2 SCREW (M6 x 25) 40 4.525 1 CABLE26 1 SCREW (M8 x 20)(MANUAL) 30 3.427 1 SCREW (M6 x 10)(MANUAL) 60 6.828 3 J CLAMP (Qty. of 2 required on Manual)29 1 HARNESS ASSEMBLY–Engine30 1 FUSE ELECTRIC31 1 PLUG32 3 GROMMET33 3 BUSHING34 3 WASHER35 3 SCREW (M6 x 25) 100 11.336 1 HARNESS-Ignition37 3 CDM ASSEMBLY38 3 HI-TENSION CABLE39 3 BOOT

3 SPARK PLUG (NGK# BP8H-N-10) 20 27.1

403 SPARK PLUG (NGK#BPZ–8H–N–10) 20 27.1

403 SPARK PLUG (NGK#BUZ8H) 20 27.13 SPARK PLUG (NGK#BP8HS-10) 20 27.1

41 6 SCREW (M6 x 14) 60 6.842 1 HARNESS-Power MANUAL43 1 HARNESS


Theory of OperationThis outboard ignition system is alternator driven(distributor-less) capacitor discharge system. Majorcomponents of the ignition system are the flywheel,stator, trigger, capacitor discharge modules (CDM’s)and spark plugs. Each capacitor discharge modulefunctions as a combination switchbox and secondaryignition coil.

Capacitor Charging #1 CDMThe STATOR assembly is mounted to the block be-low the flywheel and has 3 CAPACITOR CHARGINGCOILS wound in series. The FLYWHEEL is fitted with6 permanent magnets inside the outer rim. The fly-wheel rotates the permanent magnets past the ca-pacitor charging coils causing the coils to produceAC voltage (260–320 volts). The AC voltage is thenconducted to the CAPACITOR DISCHARGE MOD-ULES (CDM), where it is rectified (DC) and stored ina capacitor. The stator voltage return path is throughthe ground wire of the other CDM and back throughthat CDM’s charging coil wire to the capacitor charg-ing coils.

BLK

GRN/WHTWHT/GRNYEL

YEL

BRN

BLK

WHT

+

+

+

_

_

_

WH

T/G

RN

PP

LB

RN

BLK

BLK

/YE

L

BR

N

BLK

/YE

L

BLK

BLK/YEL

2

3

PPL

SCR-

CAPACITOR-

COIL-

DIODE-

a b

c

d

e

f

g

h

i

j

1

a - Battery Charging Coilsb - Trigger Coilsc - Capacitor Charge Coilsd - CDM #1e - CDM #2

f - CDM #3g - Rev. Limiter (Not Used On All Models)h - To Ignition Switchi - Stop Switchj - To Voltage Regulator


Capacitor Charging #2 & #3 CDMThe flywheel rotates the permanent magnets pastthe capacitor charging coils causing the coils to pro-duce AC voltage (260–320 volts). The opposite volt-age pulse is then conducted to the CAPACITOR DIS-CHARGE MODULES (CDM), where it is rectified(DC) and stored in a capacitor. The stator voltage re-turn path is through the ground wire of the other CDMand back through that CDM’s charging coil wire to thecapacitor charging coils.

NOTE: #1 CDM stator voltage return path is througheither CDM #2 or #3. The return path for CDM #2 and#3 is through CDM #1, if #1 stator wire is discon-nected the engine will die (the stator circuit is incom-plete and the capacitors cannot be charged).

BLK

GRN/WHTWHT/GRNYEL

YEL

BRN

BLK

WHT

+

+

+

_

_

_

WH

T/G

RN

PP

LB

RN

BLK

BLK

/YE

L

BR

N

BLK

/YE

L

BLK

BLK/YEL

2

3

PPL

SCR-

CAPACITOR-

COIL-

DIODE-

a b

c

d

e

f

g

h

i

j

1




#1 Cylinder Trigger CircuitThe TRIGGER assembly (also mounted under theflywheel) has one coil for each cylinder. These coilsare mounted adjacent to the flywheel center hub.The center hub of the flywheel contains a permanentmagnet with two north–south transitions.As the flywheel rotates, the magnet north–south tran-sitions pass the trigger coils. This causes the trigger

coils to produce a voltage pulse which is sent to therespective capacitor discharge module (CDM). Apositive voltage pulse (N–S) will activate the elec-tronic switch (SCR) inside the capacitor dischargemodule (CDM). The switch discharges the capacitorvoltage through the coil primary windings. The returnvoltage pulse exits the CDM through the ground wireand returns through the trigger ground.

BLK

GRN/WHTWHT/GRNYEL

YEL

BRN

BLK

WHT

+

+

+

_

_

_

WH

T/G

RN

PP

LB

RN

BLK

BLK

/YE

L

BR

N

BLK

/YE

L

BLK

BLK/YEL

2

3

PPL

SCR-

CAPACITOR-

COIL-

DIODE-

a b

c

d

e

f

g

h

i

j

1




Ignition Coil CircuitAs the capacitor voltage flows through the primarywindings of the ignition coil, a voltage is induced intothe ignition coil secondary windings. This secondaryvoltage rises to the level required to jump the sparkplug gap and return to ground. This secondary volt-age can, if necessary, reach approximately 40,000volts. To complete the secondary voltage path, thereleased voltage enters the ground circuit of CDMmodule.

BLK

GRN/WHTWHT/GRNYEL

YEL

BRN

BLK

WHT

+

+

+

_

_

_

WH

T/G

RN

PP

LB

RN

BLK

BLK

/YE

L

BR

N

BLK

/YE

L

BLK

BLK/YEL

2

3

PPL

SCR-

CAPACITOR-

COIL-

DIODE-

a b

c

d

e

f

g

h

i

j

1




Stop CircuitTo stop the engine, the stop switch is closed allowingthe capacitor charge current from the stator to draindirectly to ground.

NOTE: The CDM contains a zener diode (not shownfor clarity). This diode prevents overcharging of thecapacitor (and possible failure) if the SCR does notreceive a trigger pulse.

BLK

GRN/WHTWHT/GRNYEL

YEL

BRN

BLK

WHT

+

+

+

_

_

_

WH

T/G

RN

PP

LB

RN

BLK

BLK

/YE

L

BR

N

BLK

/YE

L

BLK

BLK/YEL

2

3

PPL

SCR-

CAPACITOR-

COIL-

DIODE-

a b

c

d

e

f

g

h

i

j

1




Rev Limiter CircuitThe rev limiter is activated through the purple wirewhen the key switch is rotated to the “on” position.The rev limiter uses a trigger signal (brown wire) todetermine engine speed or rpm. If the engine speedexceeds the specified rpm, the rev limiter will groundout the CDM capacitor charge. The capacitor voltageflows through the black/yellow wires into the rev limit-er and to engine ground through the black wire.

BLK

GRN/WHTWHT/GRNYEL

YEL

BRN

BLK

WHT

+

+

+

_

_

_

WH

T/G

RN

PP

LB

RN

BLK

BLK

/YE

L

BR

N

BLK

/YE

L

BLK

BLK/YEL

2

3

PPL

SCR-

CAPACITOR-

COIL-

DIODE-

a b

c

d

e

f

g

h

i

j

1




Ignition ComponentDescription

Capacitor Discharge Module (CDM)Each module contains an ignition coil and amplifiercircuitry which produces approximately 45,000 voltsat the spark plugs.

Trigger CoilLocated under flywheel. Is charged by single magneton flywheel hub. Trigger pulses are sent to CDM.

Stator AssemblyLocated under the flywheel in the stator assembly are12 coils (6 for manual stator), 3 ignition charge coilsand 9 auxiliary (3 for manual) power coils wound inseries that provide voltage to the CDM’s and battery/auxiliary circuits respectively.

FlywheelContains 6 magnets (12 pole) around circumference.Has one magnet on inner hub for trigger. Outer mag-nets are for battery charge coils and ignition chargecoils.

NOTE: Electric start model flywheel shown.


CDM (P/N 827509A_) Troubleshooting

Chart 1- CDM Trouble Shooting Flowchart

Step Action Value Yes No Tools

1 Verify High Tension Leads, SparkPlug and Spark Boots are in goodcondition. Inspect wires for chafing.

Visual Inspection

– Step 2 ReplaceFailed Com-ponent

Step 2

High Tensionlead pin P/N84-813706A56

2 Verify 4 Pin Connector Integrity

Visual Inspection

– Step 3 Repair/Re-place Con-nector Com-ponents

Step 3

–

3 Verify Ground from CDM connectorto block

0.2 Ohmsand below *

Step 4 CorrectGround Path

Step 4

DMT 2000 Digi-tal Tachometer/Multi-meter P/N91-854009A1 &DVA Adaptor91-89045-1Test Harness P/N84-825207A2

4 Test all CDMs at Cranking withSpark Gap Tester

Spark on All CDMs?Will spark jump a 7/16 in. (11.11 mm) gap?

7/16 in.(11.11 mm)gap

If at leastone CDMhas spark,continue withChart #3

Continuewith Chart #2

Spark Gap Tes-terP/N 91-850439

NOTE: * To obtain accurate reading, short test meter leads together and subtract value from reading or adustmeter to zero.CDM (P/N 827509A_)

A B C D

a - Groundb - Black/Yellowc - Trigger Connectiond - Stator Connection


CDM Stop Diode Troubleshooting2 Cyl.: CDM #1 gets its charging ground path through CDM #2.CDM #2 gets its charging ground path through CDM #1.A shorted Stop Diode in either CDM would prevent the opposite one from sparking.

1 2

3 Cyl.: CDM #1 gets its charging ground path through CDM #2 or #3.CDM #2 and #3 get their charging ground path through CDM #1.A shorted Stop Diode in CDM #1 would prevent CDMs #2 and #3 from sparking.A shorted Stop Diode in CDM #2 or #3 would prevent CDM #1 from sparking.

1 2 3

4 Cyl.: CDM #1 and #2 get their charging ground path through CDM #3 or #4.CDM #3 and #4 get their charging ground path through CDM #1 or #2.A shorted Stop Diode in CDM #1 or #2 would prevent CDMs #3 and #4 from sparking.A shorted Stop Diode in CDM #3 or #4 would prevent CDM #1 and #2 from sparking.

1 2 3 4


Chart 2-CDM Trouble Shooting Flowchart

(NO SPARK ON ANY CDM)


1 With the key switch ON:Verify continuity between BLK/YELharness wire and ground.

This Test Checks:Lanyard Switch

Key Switch

Rev Limiter (external)

Chafed BLK/YEL wire

CDM Stop Circuit

NO continuity Step 2 Repair or Replace Com-ponent

Run EngineVerify Repair

Step 7

DMT 2000 Digi-tal Tachometer/Multi-meterP/N91-854009A1 &DVA Adaptor91-89045-1

2 Un-plug all CDMs and verify conti-nuity between disconnected BLK/YEL harness wire and ground.

This Test Checks:CDM Harness

NO continuity Step 3 Repair or Replace Com-ponent


Step 7

DMT 2000 Digi-tal Tachometer/Multi-meter P/N91-854009A1 &DVA AdaptorP/N 91-89045-1

3 Connect CDM one at a time

This Test Checks:Individual CDM Stop Circuits

Resistance willrise with eachCDM connected,full continuity indi-cates shortedCDM stop circuit.*

Step 4 Repair or Replace Com-ponent


Step 7

DMT 2000 Digi-tal Tachometer/Multi-meter P/N91-854009A1 & DVA AdaptorP/N 91-89045-1

TPI/CDM TestHarness84-825207A2

4 Check Stator

Resistance between GRN/WHTand WHT/GRN

Open circuit voltage at crankingshould be no less than 100 Voltson the DVA

660-710 Ohms2, 3, 4 Cyl. Models

Step 5 Replace Stator


Step 7

DMT 2000 Digi-tal Tachometer/Multi-meter P/N91-854009A1 &DVA Adaptor91-89045-1

5 Check Trigger/Crank Shaft Posi-tion Sensor Output:

Cranking with CDM disconnected.

Cranking with CDM connected.

1 Volt and above -CDM discon-nected.

0.2 - 5 Volts- CDM connected.

Step 6 2, 3, & 4 CylReplace Trig-ger


Step 7



NOTE: *Diode Readings: Due to the differences in test meters, results other than specified may be obtained.In such a case, reverse meter leads and re-test. If test results then read as specified CDM is O.K. The diodemeasurements above will be opposite if using a Fluke equivalent multimeter.


CHART #2 (NO SPARK ON ANY CDM) (CONTINUED)



7/16 in. (11.11 mm) gap

Step 7 Verify All Pre-ceding Steps

Spark Gap Tes-ter P/N91-850439

7 If mis-firing is in a repeatablerange:

Perform DVA readings on statorand trigger at all running speeds.*

Stator: 200 Volts andabove

Trigger:2 Volts and above

Run EngineVerifyRepair

END

Refer to *NoteBelow



NOTE: * Stator tests will only isolate problem down to a charging pair. Further testing is necessary to determinefaulty CDM. Disconnecting one CDM of the charging pair is recommended.


Chart 3-CDM Troubleshooting Flowchart

(AT LEAST ONE CDM HAS SPARK)


1 Resistance Check ALL CDMs Refer to chart Step 3 Replace anyCDMs thatdo not passspecifica-tions even ifthey fire

Step 2



Spark on All CDMsWill spark jump a 7/16 in. (11.11 mm) gap?

7/16 in. (11.11 mm)gap


Step5

Step 3 Spark Gap Tes-ter P/N 91-850439

3 Check Trigger Output:

Cranking with CDM disconnected.

Cranking with CDM connected.

1 Volt andabove - CDM disconnected.

0.2 - 5 Volts -CDM connected.

Step 4 2, 3, & 4 Cyl- ReplaceTrigger


Step 5





7/16 in. (11.11 mm)gap


Step5

Replace anynon-firingCDMs

Step 5

Spark Gap Tes-ter P/N 91-850439

5 If mis-firing is in a repeatablerange:

Perform DVA readings on statorand trigger at all running speeds.*

Stator: 200 Volts andabove

Trigger:2 Volts andabove


END

Refer to*Note Below.



* Note: Stator tests will only isolate problem down to a charging pair. Further testing is necessary to determinefaulty CDM. Disconnecting one CDM of the charging pair is recommended.


CDM Test with DMT 2000 Multi-meter 91-854009A1IMPORTANT Spark plug wires are screwed into CDM.

A B C D

a - Groundb - Black/Yellow

c - Trigger Connectiond - Stator Connection

A resistance check is required and can be performed on the CDM as follows:

NOTE: This test can be performed using the test harness (P/N 84-825207A2). DO NOT connect the test harnessplug to the stator/trigger engine wire harness.

Set meter to for diode check.

CAPACITOR DISCHARGE MODULE

Circuit TestConnect Negative

(–)Meter Lead To:

Connect Positive(+)

Meter Lead To:Diode Check Setting

(Auto Range)

Stop Diode Forward Bias

Green (D)/ orGreen test harness

lead

Black/Yellow (B)/ orBlack/Yellow test

harness leadOUCH or O.L. OUCH or O.L.

Stop DiodeReverse Bias


harness lead


lead0.45-0.8 V 1.0-4.0 mΩ

Return GroundPath Diode,

Reverse Bias


lead

Ground Pin (A) orBlack test harness

lead0.45-0.8 V

1-30 mΩ, thenslowly increases to

OUCH or O.L.


Forward Bias

Ground Pin (A)/ orBlack test harness

lead


leadOUCH or O.L. 1.0-4.0 mΩ

CDM Trigger InputResistance


lead

White (C)/ or Whitetest harness lead

0.45-1.5 V(Not a perferred

test)

1000 - 1300Ohms

Coil SecondaryImpedance


lead

Spark PlugTerminal

(At Spark PlugBoot)

0.45-1.5 V(Not a perferred

test)900 - 1200 Ohms

*Diode Readings: Due to the differences in test meters, results other than specified may be obtained. In sucha case, reverse meter leads and re-test. If test results then read as specified CDM is O.K. The diode measure-ments above will be opposite if using a Fluke equivalent multimeter.

NOTE: If CDM checks good, a secondary test can be performed to ensure that CDM is good when running hot.Heat CDM with hot air gun to approximately 85 C (185 F). Repeat Resistance test above and Test 4 on Chart1 while hot.


CDM Test with Volt/Ohm/DVA Meter 91-99750A1IMPORTANT Spark plug wires are screwed into CDM.

A B C D

a - Groundb - Black/Yellow

c - Trigger Connectiond - Stator Connection

A resistance check is required and can be performed on the CDM as follows:

NOTE: This test can be performed using the test harness (P/N 84-825207A2). DO NOT connect the test harnessplug to the stator/trigger engine wire harness.

CAPACITOR DISCHARGE MODULE

Circuit TestConnect Negative

(–)Meter Lead To:

Connect Positive(+)

Meter Lead To:

OhmsScale Results:

Stop Diode Forward Bias


lead


harness lead

R x 100Diode Reading*

Continuity

Stop DiodeReverse Bias


harness lead


lead


No Continuity


Reverse Bias


lead


lead


No Continuity


Forward Bias


lead


lead


Continuity

CDM Trigger InputResistance


lead

White (C)/ or Whitetest harness lead

R x 100 1000 - 1250Ohms

Coil SecondaryImpedance


lead

Spark PlugTerminal

(At Spark PlugBoot)

R x 100 900 - 1200 Ohms

*Diode Readings: Due to the differences in test meters, results other than specified may be obtained. In sucha case, reverse meter leads and re-test. If test results then read as specified CDM is O.K. The diode measure-ments above will be opposite if using a Fluke equivalent multimeter.

NOTE: If CDM checks good, a secondary test can be performed to ensure that CDM is good when running hot.Heat CDM with hot air gun to approximately 85 C (185 F). Repeat Resistance test above and Test 4 on Chart1 while hot.


Ignition Test Procedures

Direct Voltage Adaptor (DVA) Test

CAUTIONDVA checks can be made while cranking enginewith starter motor. To prevent engine from start-ing while being cranked, all spark plugs must beremoved.

CAUTIONTo protect against meter and/or component dam-age, observe the following precautions:

• INSURE that the Positive (+) meter lead isconnected to the DVA receptacle on the me-ter.

• DO NOT CHANGE meter selector switch posi-tion while engine is running and/or being“cranked”.

NOTE: Each CDM is grounded through the enginewiring harness via the connector plug. It is not neces-sary to have the CDM mounted on the ignition platefor testing.

1. Remove all spark plugs.

2. Insert spark gap tool (P/N 91-63998A1) into eachspark plug boot and attach alligator clips to agood engine ground.

3. Disconnect remote fuel line from engine.

4. Make sure all CDMs are plugged in.

5. Test Stator and Trigger voltage to CDM:

a. Install test harness (84-825207A2) betweenignition harness and CDM.

bac

a - Stator/Trigger Harnessb - Test Harness (84-825207A2)c - Capacitor Discharge Module

b. Test each CDM.

Stator Output Test 400 DVAScale

Positive MeterLead (+)

NegativeMeter Lead (–)

DVAReading

Connect toGreen TestHarness Lead

Connect toBlack Test Har-ness Lead

100 - 320

c. If only one CDM stator reading is below speci-fications, replace that CDM. If all CDM statorvoltage readings are low, go to “Testing StatorResistance”.

GR

N BLK

d. Test each CDM.

Trigger Output Test 2 DVA Scale



DVAReading

White TestHarness Lead

Black Test Har-ness Lead 0.2 - 2.0

If reading is below specifications, replace trigger. Ifreading is above specifications, check CDM.


NOTE: If voltage remains low after installing a newtrigger, replaced CDM.

WHT

BLK

ENGINE RUNNING AT IDLE

It is not necessary to perform this test if the voltage out-put was tested in the previous step.

Stator Output Test 400 DVAScale



DVAReading

Connect toGreen TestHarness Lead

Connect toBlack Test Har-ness Lead

200 - 350

If stator output is low, go to “Testing Stator Resis-tance”.

Trigger Output Test 20 DVA Scale



DVAReading

White TestHarness Lead

Black Test Har-ness Lead 2 - 8 Volts

If reading is below specifications, replace trigger. Ifreading is above specifications, check CDM.

NOTE: If voltage remains low after installing a newtrigger, replace CDM.

Resistance Tests

TRIGGER

A resistance test is not used on the trigger. Test triggeras outlined under “Testing Voltage Output to CDM” -“Trigger Output Test”.

STATOR

1. Disconnect stator leads.

NOTE: Resistance varies greatly with temperature.Measurements should be taken with an ambient tem-perature range of 65° to 85° F.

Stator Resistance TestR x 1 Ohms

S lPositive MeterLead (+)


Scale orAuto RangeDMT 2000

Connect toWhite/Greenstator lead

Connect toGreen/Whitestator lead

660-710

385-4052.5 L

990-12103.0 L

Connect toWhite/Greenstator lead

Connect to en-gine ground No continuity

Connect toGreen/Whitestator lead

Connect to en-gine ground No continuity

IMPORTANT If all CDM stator output voltage islow and stator resistance tests are within specifi-cations, then each CDM (one at a time) must bereplaced with a CDM known to be good until sta-tor output voltage returns to proper levels. Thisprocess of elimination will reveal a defectiveCDM.

RX1


Flywheel Removal andInstallationREMOVAL

1. Remove flywheel cover from engine.

WARNINGEngine could possibly start when turning fly-wheel during removal and installation; therefore,disconnect (and isolate) spark plug leads fromspark plugs to prevent engine from starting.

2. Disconnect spark plug leads from spark plugs.

3. While holding flywheel with flywheel holder(91-52344), remove flywheel nut and washer.

55332aa - Flywheel Holder

4. Install a crankshaft Protector Cap (91-24161) onend of crankshaft, then install Flywheel Puller(91-849154T1) into flywheel.

5. Hold flywheel tool with wrench while tighteningbolt down on protector cap. Tighten bolt until fly-wheel comes free.

55333

a

a - Flywheel Puller

NOTE: Neither heat nor hammer should be used onflywheel to aid in removal as damage to flywheel orelectrical components under flywheel may result.

6. Remove flywheel. Remove flywheel key.

7. Carefully inspect flywheel for cracks or damage.

8. Inspect crankshaft and flywheel tapers for wornor damaged key ways.

9. Check for loose or damaged flywheel magnets(outer rim and center hub). Replace flywheel ifnecessary.

INSTALLATION

1. Install flywheel key in crankshaft slot with outeredge of key parallel to center line of crankshaft.

a

a - Flywheel Key

2. Align slot in flywheel center bore with flywheelkey and install flywheel onto crankshaft.

3. Install washer and nut.

4. Hold flywheel with Flywheel Holder (91-52344);torque nut to 125 lb. ft. (169.5 N·m).

55332aa - Flywheel Holder


Stator Removal andInstallationREMOVAL

1. Remove flywheel. See “Removing Flywheel” InThis Section.

2. Remove yellow stator leads from rectifier/regula-tor leads.

3. Disconnect all stator leads from CDM wire har-ness.

NOTE: Removal of ignition plate may be necessaryto gain access to stator leads.

4. Remove screws and lift stator off bearing cage.

55330

a

a

a - Screws

INSTALLATION

1. Set stator on bearing cage. Secure with screws.Screws threads should be lightly coated with loc-tite 222 and torqued to 60 lb. in. (6.8 N·m).

55330

a

a

a - Screws

2. Connect yellow stator leads to yellow voltageregulator leads (electric models).

3. Connect all stator leads to corresponding CDMwire harness.

4. Install flywheel. See “Installing Flywheel” in thissection.

Trigger

REMOVAL

1. Remove flywheel. See “Removing Flywheel” inthis section.

2. Remove stator. See “Removing Stator” in thissection.

3. Disconnect trigger leads from CDM wire harness.


4. Disconnect link arm and remove trigger.

19459

a b

a - Link Armb - Trigger

5. Lift trigger off bearing cage.

INSTALLATION

1. Install trigger and connect link arm.

19459

a b

a - Link Armb - Trigger

2. Place trigger on bearing cage.

3. Route lead wires under ignition plate and down tothe CDM wire harness.

4. Connect corresponding trigger leads to CDMwire harness.

5. Install stator. See “Installing Stator” in this sec-tion.

6. Install flywheel. See “Installing Flywheel” in thissection.

7. Check engine timing. See “Engine Timing” inSection 2C.

CDM

REMOVAL

WARNINGAlways disconnect battery and disconnect sparkplug leads from spark plugs before working onmotor.

1. Disconnect CDM wire harness plug.

2. Remove screws securing CDM to ignition plate.

INSTALLATION

1. Position CDM on ignition plate. Install screws,torque to 60 lb. in. (6.8 N·m).

2. Connect CDM wire harness plug to CDM.

55042

ab

a - Wire Harness Plugb - Screws

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